Well it is Stupid, but I found a way to trick my printer driver into accepting custom size paper for Report Forms.

I had tried everything (thank you for all the suggestions) 4 different print drivers, several custom sizes...etc.

But in the end I had to tell the print server that the custom size was 10.5"x17" and tell my printer control panel that custom size was 9"x12"

If anyone has been following, I originally had a custom size envelope (9"x12") that printed perfect when we were using workstations that ran Win98. When upgrading the workstations to Win 2000, all of the sudden Printing was way out of alignment.

Thanks,
Scott